How an ABB’s Energy-Saving Investments Transform Operations

Businesses all over the world are working to streamline their operations to boost their efficiency and conserve energy.
ABB Electrification Services’ facility in Florence, South Carolina, USA is a 150,000sq ft aftermarket support and service centre that has transformed its operations by implementing cutting-edge energy-saving measures.
The site employs around 100 people and is a critical hub for power infrastructure maintenance.
Specialising in the repair, retrofit and upgrade of electrical distribution equipment — including switchgear, breakers and complex electrical systems — the team supports critical infrastructure across industrial and commercial sectors across the US.
The energy efficiency approaches implemented here not only slash its carbon footprint but also saves more than US$150,000 annually in energy costs.
ABB: Leveraging technology for energy efficiency
ABB Electrification Services is setting an example on how operations can be streamlined for both the benefit of business as well as sustainability.
Its Florence site — one of ABB’s largest in the US — is powering ahead with a range of sustainable initiatives that have been implemented in recent years.
- The site saw a HVAC overhaul, with the aging air conditioning system retrofitted with new roof units and modern control automation, eliminating the need for natural gas heating
- Narrower restricted flow pipes and low-flow faucets were installed to reduce water consumption
- Florence’s 90,000 sq ft shopfloor saw its 240v metal halide lighting replaced with modern LED units, an investment that paid for itself in less than three years
- State-of-the-art software from Ndustrial was implemented to provide real-time insights into energy usage patterns
Ndustrial’s real-time monitoring transforms ABB plant
The installation of Ndustrial's monitoring software has been a game-changer for the Florence team.
By placing more than 20 monitors on electrical equipment at key points throughout the facility, Ndustrial’s software provides consumption data to an online dashboard, offering actionable insights
Shawn Shockey, Manager of Manufacturing for ABB Electrification Service says: “One of the first things we noticed were peaks in power demand for the AC system throughout the day and that immediately makes you ask what’s going on.
“You want to know what’s happening at that time of day and what’s causing the extra demand.
“One thought we had was that because the warehouse is not air conditioned, perhaps the system was working extra hard at times to normalise the overall temperature. We thought we should do the math on this and find out if it would be more efficient to install another AC unit in the warehouse than pay the additional energy costs.
“Now we are bringing in an outside auditing firm to do the analysis and confirm our suspicion.”
ABB and Ndustrial’s data-driven approach has already led to significant discoveries and improvements:
- Identification of unnecessary weekend operation of air compressors, leading to new energy-saving measures
- Potential for further optimisation in warehouse temperature control, currently under analysis
“Ndustrial is a powerful tool for helping businesses understand their energy intensity — the amount of energy, emissions and cost required for one unit of production,” Shawn adds.
“We are only just scraping the surface of what the software is capable of.”
The next step: Adding solar
The next major project for the Florence team is a huge solar farm with 1500 panels across three acres, capable of generating 840kWac of electricity.
By installing this infrastructure, ABB is edging the plant towards self-sufficiency and eliminating its monthly electricity bill of up to US$15,000 altogether.
Shawn explains: “You need to play the long game when it comes to investing in renewables. There is a plethora of fast-moving new technology in this space, so it pays off to do your research, get good advice and make sure you select the correct long-term solution the first time.
“Alongside the solar farm, we will be introducing the latest Battery Energy Storage System (BESS) solutions to ensure a consistent, uninterrupted supply of electricity even when the sun isn’t shining.
“You've got to be patient and vigilant with this type of project but ultimately the effort pays off.”
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